Method of forming composite boxes



July 25, 1933-.

J. s. STOKES METHOD OF FORMING COMPOSITE BOXES 6 Shegts-Sheet l Filed Sept. 8, 1930 INVEN TOR. 9% 3 MM MalQsZQJ July 25, 19330 J. 5. STQKES METHOD OF FORMING COMPOSITE BOXES Filed Sept. 8, 1930 6 Sheets-Sheet 2 IN VEN TOR. v? M224 Q Q ATTORNEY.

July 25, 1933. J. s. STOKES METHOD OF FORMING COMPOSITE BOXES Filed Sept. 8, 1930 6 Sheets-Sheet 3 Q NRQ HQMMQ Q .N

I Q INVENTOR.

UQA (f. Q/ZZZK a! Qw ATTORNEY.

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July 25, 1933. J. 5. STOKES 1,

METHOD OF FORMING COMPOSITE'BOXES Fild Sept. 8, 1930 6 Sheets-Sheet 4 I 1 N VEN TOR.

ATTORNEY.

July 25, 1933. J. s. STOKES METHOD OF FORMING COMPOSITE BOXES 6 Sheets-Sheet 5 Filed Sept. 8, 1930 R QK RQ mm mmm INVENTOR.

1 ATTORNEY.

July 25, 1933. J. s. STOKES METHOD OF FORMING COMPOSITE BOXES 6 Sheefls-Sheet 6 Filed Sept. 8, 1930 J M /M 4 Mwzw 1 ATTORNEY.

Patented July 25, 1933 renter entree STATES, earenrzorrice 1 JOHN S. STOKES, F HUNTING-DON VALLEY, PENNSYLVANIA, ASSIG-NOR TO STOKES AND Y making boxes hereinafter SMITH COMPANY, OF PHILADELPHIA, PENNSYLVANIA, A CORPORATION OF PENN- SYLVANIA METHOD or FORMING ooivrrosrrn Boxes Application filed September 8, 1930. Serial No. 480,432.

My invention relates to the formation of composite boxes formed from a plurality of separate components. I i

In accordance with my invention, box components adapted to form the bottom and side walls of a box are cut'in succession from a continuous strip, as a roll, of box ma terial; preferably, prior to severing of the strip, it is scored, as transversely, to define the bottom and side panels, and thereafter tabs, preferably cut from continuous strips, are applied to project beyond the sides of components and in some forms of my 1nvention-also beyond the ends thereof.

At a box forming station, each of the components is brought into proper box-l forming position with other box components forming the end walls, preferably also out from continuous strips, and the projecting tabs folded to attach the separate components to form a box.

Also in accordance with my invention, the strips ofv box material maybe covered with paper, or equivalent, removed from rolls and applied prior to cutting of the components therefrom and preferably also before attachment of tabs thereto.

Further in accordance with my invention, labels may be applied to strips of box material, covered or uncovered, prior to assembly of the components and preferably before I severing V of the strip.

My invention also resides in methods of described and claimed.

' For an understanding of my invention and for illustration of several methods embodyin it, reference is made to the accompanying drawings, in which in perspective:

Fig. 1 illustrates the scoring, tabbing, and cutting of a strip of box material;

Figs. la and 1b discloses a tabbed box component.

Fig. 2 illustrates the cutting of complementary box components from rolls of box material.

Figs. 3, l and 5 illustrate the several successive steps forming a box from the components of Figs. 1a and 2.

Figs. 6 and 7 disclose components similar to those of 1a and 16' with notched tabs.

Fig. 8 is generally similar to Fig. 2,additionally disclosing application of labels to the strips of box material. v

Figs. 9 to 11 illustrate the successive steps of forming a box from the components of Figs. 6 and 8. Fig. 12 illustrates the scoring, tabbing, and cuttingof a strip of box material.

. Figs. 12a and 13 disclosea box component resulting from the operations diagrammatically disclosed in Fig. 12, the tabs having portions projecting beyond the ends of the component. I I

Fig. 14 is similar to Fig. 2.

Figs. 15 to 18 illustratev the successive steps of forming a composite box from the components of F igs.'13 and 14.

covering,

" Fig. 19*illustrates the scoring,

and cutting of a strip of box matabbing, terial. i

Figs. 19a and 20 illustrate box component.

Fig. 21 discloses the covering of strips of box material from which complementary box components are out. J

Figs. 22 to 24 inclusive illustrate the successive steps of forming acovered and stayed box from the componentsv of Figs. 20 and 21; r

Fig. 25 illustrates the scorin covering,

tabbing, and cutting of a strip of box material. 7

Figs. 25a and 26 illustrate'the resulting box component with portions of the tabs projecting beyond the ends of the component.

Fig. 27 is generally similar to Fig. 21 and illustrates the covering of strips from which box ends are cut.

, Figs. 28 to 31 illustrate the successive steps of forming a wrapped box from the components of Figs. 26 and 27 Fig. 32 illustrates the scoring and cutting of box material, the cutting and application of covering material, and the tabbing of box components out from the roll of box material. y

Figs. 32a'and 33 illustrate the box comthe resulting V ponent resulting from the several operations of Fig. 32. V

Fig. 3a illustrates the covering and labeling of strips of box material from which end components are cut, with covering or trimming of one edge of the strip.

Figs. to 38 inclusive illustrate the successive steps of forming a box from the components of Figs. 33 and 34.

Fig. 89 is an inverted view of the box shown in Fig. 38.

Referring to Fig. 1, a strip of box material, fed or removed from the roll M, is scored or creased transversely by the knives 1, or equivalent, which engage the lower or under iii-face of the strip opposite the roll 2, the distance between the knives corresponding to the width of the bottom section b of a box. After each scoring operation, the strip may be fed to such extent that when the knives again pass across the strip the distance between adjacent sections Z) is equal to twice the height of the side panels a of the box. The dot-dash line indicates where the strip is subsequently cut by the knives 4: to separate the two adjacent side panels 8 of different box components. Preferably, before the strip is cut to form a component m having the bottom section b and side wall sections 3, tab strips 2?, fed from the rolls T and rendered adhesive by the moistening or glue-applying roll 3, are applied to opposite edges of the strip, normal to the scoring, with part of each extending for a suitable distance beyond the side of the box strip, so that when a component 97?. is cut therefrom the tabs t extend across opposite ends of the component, as clearly indicated in Fig. 1a. The component when bent along the scoring assumes the appearance of Fig. 16. Preferably, the side panels 8 are bent inwardly flat against the central portion 2) to prevent bowing of the sides of the completed box.

From the rolls E of box material, corresponding in width to the height of the box to be formed, are out the end components e'by the knives 5, the length of the component corresponding to the width of the box. Preferably, the rolls are disposed adjacent a boxforming station, for example, the form block F, against which the end components 6 are suitably held, as shown in Fig. 3. The main component m and the end wall components 6 are maintained in box-forming relation upon the form block structure, and while in this position (Fig. at) the portions of the tabs 2? projecting from the side panels 8 of the main component m are folded into adhesive engagement with the end components 6, and thereafter the central portions of the tabs 25 are bent upwardly into adhesive engagement with the end wall component e completing the per.

tabs t as above described.

formation of the box (Fig. 5) by uniting the several components 6, e and m.

To avoid the gusset fold at the lower corners of the box of Fig. 5, the portions of the tabs projecting beyond the main component 'm, may be notched as indicated in Fig. 6 to divide the projecting part of each tab into a central flap Z6 and flaps ts extending from the side panels of the wraplVith the tabs so notched, the side flaps is may be folded into engagement with the end wall component a (Fig. 10) independently of the central portion tb which is thereafter folded into engagement with the end wall component overlapping the lower portions of the vertical flaps t8, the completed box being shown in Fig. 11.

W hen. desired, labels or the like may be attached to the strip box material before it is cut into components. For example, as shown in Fig. 8, labels'Z are removed from the stacks L and applied to the under surface of the strip removed from the rolls E before cutting the strip. The end components c with the labelsattached may then be transported, against the ends of a form block to which is delivered the main component m, to which they are attached by folding of the projecting portions of the It will be appreciated that in lieu of aifixing labels, the strip may receive impressions from a printing roll orequivalent. In either event, the labeling of the box which generically includes printing, is applied to only as much of the box material as is to be used, and there is avoidedthe usual practice of printing or labeling larger quantities than are needed because of inevitable mutilation or destruction of some materials or in anticipation of future orders.

Referring to Fig. 12, the tab strips may be applied so that they project beyond the ends of the box component m to provide the turn-in portions 6m. As the scored strip is fed from the roll, the tab material removed from the rolls T is applied to the edge of the strip, the tab feeding starting slightly in advance to provide the projecting portions 25m. The knives t are operated to cut a component from the strip, and preferably simultaneously the knives (6) are operated to sever the tab strip joining this component and one previously cut. The length of each tab strip between the adjacent components is equal to twice the length of a single turn-in portion z m, so that for each reciprocation of the knives 6 a tabbed box component, as indicated in Fig. 12a, is produced. When the knives 4 open, the component cut thereby from the strip is fed forward and the application of the tab strips thereto is effected or completed, the tab feed continuing until the length of each of tabs 6 beyond the knives is equal to the length of the components m plus the turn-in portions tm. Simultaneously, the tab strips are being applied to the advancing box strips. i

5 The notching of the tabs to provide the flaps 5?),58 may be effected-at any suitable. time, either before, after, or simultaneously with cutting of the tabs by the knives 6. The tabbed blank bent into position is shown in Fig. 13, each tabhaving portions 25m projecting above the top edges of the side panels 8 and flaps ts and H) projecting outwardly beyond the ends of the side panels and bottom panel, respectively.

The main component is transported to a wrapping station, as the form block F, to which there is substantially simultaneously delivered a pair of end components 6 out from the rolls E. WVith the components in box-forming position, the Vertical flaps ts at each end of the box are folded into engagement with the corresponding end wall component 6 (Fig. 16), and thereafter the central tab portions 25?) projecting from the bottom panel 6 ofthemain component are folded upwardly into engagement with the end wall components and into overlapping relation with the vertical fiaps 258 (Fig. 17 The portions tm projecting above thetop edges of the box at the corners are folded downwardly into engagement with the interior of the box (Fig. 18). By turning in the tabs the strength of the box is greatly increased, and permits the use of much thinner tabbing material without sacrifice of strength. 7

The different boxes thus far described may be made of strips of box material M, after passing into engagement with the adhesive moistenin'g or adhesive-applying roll 7. The roll C is substantially equal in 'width to the roll M, thoughgreat exactness 5 is not required as the tab strips t removed from the rolls T, which are subsequently applied to the covered strip, conceal any parts of the strip not covered by the cover C. The knives 4 simultaneously cut the box strip, the covering strip and the tabs to form, as shown in Fig. 19a, a covered and tabbed box component adapted to form the bottom and side walls of a box. The projecting part of the tabs may, as in modifications previously described, be notched, slit- .ted, or otherwise cut to form the flaps ts, it,

' ends 6 are out are covered by sheet material removed from the rolls K, the knives 5 simultaneously cutting an endcomponent and its applied cover is from the composite strip. The rolls 8 apply adhesive to, .or moisten adhesive already upon, the surface of the c0v ering strip adapted to engage the box mate-- rlal.

The covered main component m with the tabmaterial projecting therefrom is delivered to a form block structure F against which the covered components 6 are held. The tab projections ts of the main component are folded into engagement with the covering material on the end wall components e (Fig. 23),.and thereafter the tab 7 portions 25?) are folded upward into engagement with the covering material k on the end wall components 6 and to overlapping relation with the flaps ts (Fig. 24). Further saving of covering material may be effected by using rolls 7c and c, which are somewhat .narrower'than the strips of box material to which they are respectively applied, relying upon the tabs to conceal the otherwise uncovered part of the box exter1or. V

The modification of my invention shown in Figs.-25 to 31isgenerally similar to that just described, but has the additional fea-- ture that the tab strips project beyond the ends of the main'component so that, as in the modification of- Figs. 12 to 18,.the upper corners of the box are reinforced by tab structure engaging the interior and exterior thereof. Briefly, after the box strip is scored or creased by the knives 1, covering material removed from the roll C is applied thereto, the knives 4 cutting the composite strip. Before cutting of the strip there may be applied to the composite edges thereof tab strips tremoved from the rolls 1 T, the knives 6 cutting the tab strips joining the boxcomponent, cut by the knives 4, to one previous.y cut and to which tab strips have been fully applied. Sinceit is desired that the tab strip shall extend beyond both the leading and trailing edges of the boxcomponent, the application of the tab strip is not completed until after-the component has been severed from the box strip by the knives at. ponent with the-tab strips projecting-therefrom, after being bentialong the scoring thereof (Fig. 26), is delivered to the form block structure F against which areheld end wall componentse, cut by knives 5 from the composite strips formed by adhesive engagement between covering strip removed The covered comtion of the'prior modifications, the boxes are formed by folding the projecting flap sections is and 29b of the tabs into engagement with the covered surfaces of the end wall components, and the portions r'm projecting above the top of the box at the cor ners downwardly into engagement with the interior of the box (Figs. 30 and 31).

, In the modification of my invention disclosed in Figs. 32 to 39 great saving ofcovering material is effected by omitting completely to cover the bottom of the box. Additionally, the appearance of the box is improved by covering the top edges. After the strip of box material removed from the roll M is transversely scored by the rolls 1, it is cut by the knives 4 forminga leading side from the strip by operation of knives 45, it

is fed in the same direction towards a third set of knives 6, and during this feeding movement tab material removed from the rolls T is applied to the blank over the covering piece as. Simultaneously therewith a second covering strip 08 is applied to the trailing part of the component, completely covering the trailing sidepanel, and project- I ing to the rear to provide the projecting portion cm and the portion 06 in adhesive engagement with the bottom portion 6 thereof. The knives 9 thereafter cut the covering material simultaneously to form a covering strip 08 applied to a component already cut from the box material and a. component as applied or being applied to the leading-edge of the strip of box material. After the knives 6 have cut the tab strips, completing the production of one box component such as shown in Fig. 320., the following, partially prepared component is again fed to the right, as viewed in Fig. 32, beyond the knives 6 during which time application of the tab strips to the edge of the component is completed or resumed. In turn, the'last step of forming this component is effected by the knives 6 cutting the tab strips. Tl1e covered tabbed main component, ready for delivery to the forming station, is shown in Fig. 33. I

The rolls K of covering material (Fig. 34) are somewhat wider than the rolls E of box material, so that the covering material after being rendered adhesive by the roller 8 and applied to the box strip projects therebe yond, the rolls 12 or equivalent turning the projecting part of the covering material over the edge of the strip and into engage ment with the other side thereof. The end wall components 6 cut from the composite strip are transported to a form block, with the covered edge of the components adjacent the top edge thereof, and withthe uncoveredflsurface of the components in engagement with the ends of the block.

lVith the components in the position shown in Fig. 36 the flaps ts of the tabs are tions cm in engagement with the box being t preferably the same in width as the turnedin portions cm of the covering material ap-' plied to the box end. components 0, as shown in Fig. 38. The projecting portions tm, of

the tabs are folded simultaneously with fold- T ing of the covering portions am. It will be understood, however, that the tabs need not project beyond the top edges of the box.

Printing or labels may be impressed upon the covering material removed from the roll K after its engagement with the box material. i I i By omitting the knives 10 the main box component m may. be completely covered with a single sheet, i. e., the bottom as well as the side walls will be covered. The box thus formed will have the feature in common with that described of having all of its top edges covered or trimmed,

In all the modifications of my invention, it will be understood that preferably as .a main box component is being prepared, end wall components are being simultaneously prepared so that in succession there are produced groups of components ready for transportation and assembly at-a boxformv ing station. All the methods are preferably continuous in that the several'stepsfollow each other without substantial delay, and the adhesive holding the tabs to the main component m is. preferably unset when the components are assembled in box-forming relation ready for attachment to each other by the projecting tab material. m

While all of the'steps of the several methods described may be performed manually, at least several of them may be effected by known mechanisms. .For example, in copendingRider application Serial No. 460,-

' 859, filed June 13, 1930, there is shown av box machine for cutting box components from continuous strips fed from rolls, and for delivering a group of box components to the form block of the machine which supports them. temporarily in box-forming position imam during tabbing or other sheet material, h

It willbe understood that other modifications may be efi'ectedwithout departing from the spirit of my invention Whose-scope is defined by the appended claims. 'At least] some of the broader aspects of the disclosure herein, are comprehended by claims ofmy copending application Serial No. 464:,833,

filed June 30, 1930.

What I claim is:

1. The method of making xes which" comprises adhesively applying tab material to a strip of box material with. portions thereof projecting beyond said strip,' sev-' V eringv the strip andltab -material applied thereto to form a component adapted to be the bottom and side walls of a box, bringing end Wall components in engagement with said first component in box-forming position, and folding the projecting tab portions into adhesive engagement with said end wall components.

2. The method of making boxes which comprises, adhesively applying tab material.

to a strip of box material with portions thereof projecting beyond said strip, severing the strip and tabpmaterial-applied thereto to form a prepared component applying .30 alabel to another strip-of box material,

severing said other strip to form a labeled box component, bringing said components in position to form walls of'a box, and folding the projecting tab material into adhesive engagement with said labeled component.

- 3. The method of making boxes which comprises, cutting box components from continuous strips of boxinaterial, applying tab strips to certain of saidcomponents" before 40 their severance with portions thereof projecting from the components, applying labels 7 to certain of said components before their severance, assembling each group of com said end wallcQmponents. into engagement with said first component in box-forming position, and folding. theprojecting tabportions into adhesive engagement with said end wall components,

5. The method or making boxes an comprises, adhesively applying tab material to a strip of box material with portions thereof projecting from the sides of the strip, independently severing 'said' strip andftab I heir attachment to each other'by the interior of the box,

ends of the component continuous strips of box material, bringing material to form a box component with portions of the tabs projecting beyond the, ends of the "component, bringing another component into engagement"-with said first component in position to form walls of a box, folding the side projecting tab portions tab portions into adhesive engagement'with 6. The inetlicd of making boxes which co'morises adhesivel a l n tab material to strip of uncovered box material with portions thereof projecting from the sides of the strip, independently severing the strip and tab mate ltl to form a box'com'ponent adapted to formthe bottom and sides'of a ,1

into adhesive en agement with said other 7 1 component, and folding the end pro ecting box with" the tabs projecting beyond the p ,severing uncovered strips of box material to forinend'w'all'coin- 'ponents; "bringing said first component into ei'igagemerit with said end wall component inposition to form a box,;and folding the side projecting tab portions intoadhesive engagement with the exterior faces of the end wall components and the end projecting portions over the top of-and down- Wardly into adhesive engagement with the interior faces of said components.

7. The methodiof making boxes which comprises, adhesively applying sheet material to a strip of box material to project-beyond the edges thereof, 'cuttingthe strip and attached sheet material to produce a box 7 component adapted to fornitlie bot-tom and side walls of a box, cutting the projecting sheet material'to'form flaps, bringingend' 1 wall components into engagement 7 with said first component in" box-forming position,

and folding the projecting flaps ateach end of the box into {adhesive engagement with c the corresponding end wall componentsand into overlapping adhesives engagement.

8. The method of making. boxes which comprises, feeding a sti'ipof'box material froma roll thereof, transversely scoring the strip, applyi ig'tab strips to the score strip to project beyond' the edges thereof, cutting the tabbed, scored strip to produce box com- 7 ponents, ea eh adapted to form and side walls of a-fbox'with tabs coexten- "sive, therewith,

material from rolls thereof, cutting end,

wall components; therefrom, and uniting a group of components i'nbo'x-forming posifeed other strips other;

the bottom tion by the tabs projecting from one of" them; V g g Z 9. The methodef making boxes which comprises,'feediiigffrom rolls equal lengths of strips or-baa material,- covering material, 12?

and tab material, effecting adhesive engage- .ment of said strips, cutting the composite stripto produceiaicovered, tabbed boxcomv 7 poii'ent adaptedform the bottom side walls ofaboewith tab inaterial projecting-imam beyond the sides thereof, feeding from other rolls and effecting adhesive engagement between equal lengths of strips of box and covering material, cutting thev composite strips to produce covered box end wall components, and uniting the components in boxforming relation by the projecting tab material. 10. The method of making boxes which comprises, feeding strips of box naterial and covering material to like extent from rolls of equal width, effecting adhesive engage- -ment of said strips, cutting the covered strip to produce box components each adapted to form the'bottom and side walls of a box, feeding strips of box material and covering material to like extent from rolls .correspending in width to the box height, effecting adhesive engagement of and cutting the strips to formcovered box end walls, and uniting groups of components in box-formingposition by projecting tab material applied to covered strip material before cut-' edges and into engagement with the other sides, assembling unattached pieces of the covered box material in box-forming position, folding the covering material projecting above the side walls over the top thereof and into engagement with the interior surface, and uniting the covered pieces in boxforming position by tabs overlying the side and bottom edges of the box at each end thereof. 7 i r 12. The method of making a box which comprises, adhesively 'applyingto one side of box material destined to formthe bottom and side walls of a box, sheet covering material extending beyond the edges thereof destined tobe the'topedges of the box side walls, applying tab strips to the other edges of the material to project therebeyonchadhesively applying other sheet covering material to one side of other box material adapted to form box ends and over the edges thereof destined to be top edges and into engagement with the other side, assembling pieces of the covered material in box-form ing position, and while the pieces are in such position, folding the sheet material projecting above the side walls of the box over the top edges thereof into engagement with the box, interior and the-projecting tab portions into engagement with the end wallpieces.

13. The method of making a boxwhich terial extending beyond the edges thereof comprises,-Tadhesively applying to one side of box material destined to form the bottom and side walls of a box, sheet covering madestined to be the top edges of the box side walls, applying tab strips to the other edges of the n'iaterial to project beyond the'said sides and the ends thereof, adhesively applying other sheet covering material to one side of other boxmaterial destined to form 15 box ends and over the edges thereof destined to be top edges and into engagement with theotherside, assembling the pieces of covered material in box-forming position, and

while the pieces are insuch position, fold- L39 ing the sheet covering and tab material projecting above the side walls of the box over the top edges thereof intoengagement with the box interior and the tab portions project ing from the ends of the side and bottom walls into engagement with the end wall pieces." r

14; The method" of making boxeswhich comprises, effecting adhesive engagement of strips of box material and covering-material fed from rolls of substantially similar width, independently; cutting the strips to produce a box component adapted to form the. bottom and side-walls of a box and with the covering material projecting-beyond the ends thereof, applying tab material fed from rolls thereof to said component vto project beyond thesides thereof, effecting adhesiverengagement between other strips of box material and covering material fed from rolls with the coveringmaterial projecting beyond the box material, folding the pro jecting covering material over the edge of and into engagement with the other side of the box material, thereafter cutting the com-3.

posite' strip to form box ends, assembling the ,box'compo'nents in position .to'form a box the covered edges of the end components Iforming top edges of the box, folding the sheet covering material projecting above the 7.31

side walls of the box to complete covering of the top edges of thebox; and folding the projecting tabs into engagement with the end wall components to unite them withsaid J15 first component.

15. The continuous method of making boxes which comprises cutting box components each adapted to form the bottom'and side wall of and box components achadapted t0 form end walls of a from rolls "of box material corresponding 'in width respectivelyto the length and height of the boxes to be formed, adhesively applying strip-like'tab material to project beyond strip box material before cutting thereof,

and beforesetting of adhesive on the tab material, assembling in succession the groups of box components in box-forming position and uniting the components of each;1130

group by folding of the-projecting tab ma and uniting the components of each group by said projecting tab material.

'17. The method of making boxes which ponents in position to form a labeled box,

comprises, adhesively applying sheet cover ing material and tab strips to a strip of box ,material, cutting the composite strip to form 'box components each adapted to form the bottom and side wallsof a box with thetabs projecting at each end 'fromthe bottom andside Walls, applying sheetcovering material to other strips. of box material, cutting the composite strip to form box ends, and unit- 'ingthje components inbox-forming position by the rojecting tabs. 7

JOHN S. STOKES. 

